Electrode boiler featuring variable and controlled output

ABSTRACT

An electrode boiler featuring variable and controlled output is used for heating closed areas by producing hot water and may include an electronic processing unit, area and water sensors; priority controller; power unit; the plastic core; curved plates; metal rod; metal neutral spacer and a screw sealing-connecting the electrodes. An electrode boiler featuring variable and controlled output uses the heat rapidly generated when alternating current flows through streams of liquid. This is achieved by using metal plates and a compact cylindrical rod arranged inside a plastic core. According to the information received from the area and water sensors, the electronic processing unit allots the electric load via the power unit in order to achieve a desirable temperature. The self-regulation of the operational power load required when used simultaneously with other energy-consuming appliances, is ensured by using the priority controller.

This present developments refer to electric boilers used to heat the interior of buildings.

Electrode boilers are widely used for heating purposes in buildings. Electrode boilers use the heat generated during the flow of alternating current through streams of water. The heat is then transferred to radiators via a network of pipes.

Electrode boilers include a metal cylinder connected to the neutral conductor and an electrode connected to the current phase inside the cylinder. The cylinder and electrode are made of cast iron and there is electrical insulation at their point of contact. When the liquid flows through the cylinder, the electric current passes through and heats it.

The cylinder and electrode dimensions are standard and determine the apparatus electric output based on the electrode's contact area with the water or with the glycol-water mixture found in a closed loop circuit transferring the heat to the water inside the radiators via an exchanger.

The fact that the electrode surface is fixed is a drawback for such systems because electrical conductivity varies and is dependent on the existence of ions, the concentration, migration speed and valence thereof and on temperature variation; this results in the system not having a fixed capacity thus requiring an exchanger and a closed circuit wherein the glycol liquid is of a predetermined quality.

In case of current leakage, the cylinder is hazardous as it is not compliant with the electrical regulation, which provides for the existence of protective grounding.

Additional drawbacks to those heating systems are the following: the increased time required to reach the desirable temperature; the inability to regulate the operational electric load so as to simultaneously operate with other energy-consuming appliances; and the inability to manage and control the energy output.

Documents describing previous techniques: WO2009100486 A1/(MICROHEAT TECHNOLOGIES PTY LTD & AL) 20.08.2009, GB2268671 A/(ELECTRICITY ASS TECH, EA TECH LTD) 12.01.1994, U.S. Pat. No. 3,688,077 A/(WILLIAMS STANLEY AUSTEN) 29.08.1972, GB1499375 A/(GOETEBORGS ANALYSLABOR AB) 01.02.1978.

Pat. No. 1,008,031 and the Patent Amendment with application number 20130100705 submitted by the same applicant form part of the present developments improving the efficiency output, operational safety and the cost of manufacturing of an electrode boiler hereof featuring variable and controlled output.

A purpose of the presently-described developments is to create an electrode boiler featuring variable and controlled output in accordance with what is stated above such a boiler being more efficient, safer, less costly to manufacture and ensuring variable and controlled operation output based on the thermal load required without an exchanger and a closed loop circuit for liquids.

According to the implementations hereof, this may be achieved with the use of metal plates internally adjusted on a plastic core connected to the phase (single-phase) or phases of current (three-phase). The plastic core contains the neutral conductor, which is made of steel and includes a solid cylindrical bar surrounded by the circuit liquid. The water inside the core is heated by the electricity flowing through it and comes out using a circulator.

The electrode boiler featuring variable and controlled output takes advantage of the heat that is rapidly generated when alternating current flows through streams of liquid. The liquid heated by the electrode boiler featuring variable and controlled output flows through interconnected radiators which radiate the heat into the surrounding environment.

The efficiency output can be modified by using a priority controller, an electronic processing unit and a power unit according to the data received by the area and water sensors and by the user.

The priority controller may include a microcontroller. Given the microcontroller may be a standardised product widely used in built-in systems such as in automation and electronic products, its design features and operation are not analysed. It performs the following function: based on the consumption of power required by the remaining appliances in the facility, it distributes power first to such appliances and thereafter to the electrode boiler featuring variable and controlled output. In essence, the microcontroller receives from the facility panel-board the information concerning the power consumption, converts it into digital information and transfers it to the processing unit which uses its respective software in order to send a command to the power unit to reduce the power supplied.

The power unit may include a microcontroller and an electronic power switch (solid state relay SSR or TRIAC), which are standardised products widely used in built-in systems such as in automation and electronic products and their design features and operations are not analysed. The power unit performs the following function: it may receive commands from the electronic processing unit and distribute the electric power to the circuit.

If other power-consuming electric devices are turned on in the same electrical installation, the power unit reduces the consumption of power.

Power is supplied to the radiator via the power unit in the form of electrical pulses; electro-stimulation is achieved via electrical pulses, i.e. half-cycles of alternating current flowing through the liquid. Power is intermittently transferred to the electrical circuit via the SSRs. This is a difference as compared to all pre-existing systems transferring electrical power through liquids to generate heat. In the case of the autonomous electrode radiator, the power supply is intermittent using the power unit, and controlled by the processing unit.

The developments hereof may feature one or more of the following: a) regulation of the heat output using a priority controller, an electronic processing unit and a power unit, irrespective of the conductivity of the water flowing through the plastic core; b) the developments hereof may operate using either or both single-phase and three-phase current; when using three-phase electricity, each phase is connected to sets of three curved plates; c) the developments hereof may be adjusted via the electronic processing unit so as to operate using specific amount of power; d) the developments hereof do not require a closed circuit of liquid with a heat exchanger, thus reduces losses and improves the system's overall efficiency output.

The developments described herein may be fully understood based on the following analytical description with reference to the attached drawings, wherein:

FIG. 1 presents a diagrammatic plan view of the parts of an implementation hereof; the electronic processing unit (1); the area (2) and water (6) sensors; the priority controller (3); the power unit (4); the plastic core (5); the curved plates (7); the metal rod (8), the metal neutral spacer (9); and the screw sealing and connecting the electrodes (10).

The electronic processing unit (1) here includes a processor and a memory unit wherein the daily operation programme is stored. The water (6) and area (2) sensors, and the priority controller (3) are connected to the electronic processing unit (1).

The electronic processing unit (1) determines the operation of the power unit (4) and in essence controls the power used.

The power unit (4) receives control commands from the electronic processing unit (1) and distributes power to the circuit.

Using the priority controller (3), the power unit (4) reduces the consumption of electric power in the event that other power-consuming electric devices are turned on in the same electrical installation.

FIG. 2 shows a perspective of the plastic core (5), which is made of plastic material in replacement of a cast iron cylinder ensuring insulation and reducing the risk of electric shock as it is not under load.

The metal rod (8) is made of steel and is placed inside the plastic core (5). Insulated curved metal plates (7) are arranged around the rod (8) inside the plastic core (5) without touching each other.

The curved metal plates (7) are connected to the electric power phases. The connections in this implementation may be reverse in comparison to the existing systems in the market.

The distribution of power via the power unit (4) is controlled electronically. The power unit (4) is controlled electronically by an electronic processing unit (1). The electronic processing unit (1) controls water temperature in real time by using water sensors (6) located in the water supply input and output, and area sensors (2) respectively. According to the information received from the above sensors, the power unit (4) distributes the electrical load pursuant to the power set, so as to achieve the desirable water output temperature.

In case of malfunction in the electronic processing unit (1) or if the temperature sensor (6) shows that output water temperature exceeds 90° C., then the power unit (4) shall interrupt the power supply via a safety fuse. If a current phase is lost when operating in a three-phase connection, then the power unit (4) distributes the remaining power depending on the status of operational use; the power supply to the processing unit (1) continues uninterrupted.

The processing unit (1) controls the operation of the circulator which is placed in the system output. The circulator starts to operate when water temperature reaches 15° C. and gradually increases the water circulation speed until water reaches 40° C.; thereafter, the circulator operates constantly at maximum capacity and the heat delivered to the water is managed the power unit (4). 

1. An electrode boiler system featuring variable and controlled output for producing hot water for the purpose of heating closed areas, comprising operatively connected to each other: an electronic processing unit; one or more area sensors and liquid sensors; a priority controller; a power unit; a plastic core comprising a liquid; one or more curved metal plates; a metal rod; a metal neutral spacer; one or more screws connecting and sealing one or more electrodes; wherein the boiler produces heat that is rapidly generated when alternating current flows intermittently via electrical impulses generated by the power unit and determined by the electronic processing unit in the liquid inside the plastic core.
 2. The electrode boiler according to claim 1, wherein the metal plates are adjusted inside the plastic core and are connected to at least one phase of current supply by using the screw connecting and sealing the electrodes.
 3. The electrode boiler according to claim 1, wherein the plastic core comprises therewithin a neutral steel conductor, the neutral steel conductor comprising the metal rod which is a cylindrical compact metal rod surrounded by the circuit liquid and remains fixed using the metal neutral spacer.
 4. The electrode boiler according to claim 1 wherein the liquid inside the plastic core is heated by electric power that flows through it and comes out using a circulator that circulates the liquid and streams it to radiators via a network of pipes.
 5. The electrode boiler according to claim 1, wherein the use of the priority controller, the electronic processor unit and the power unit ensures self-regulation of any operational power load required when used simultaneously with other energy-consuming appliances.
 6. The electrode boiler according to claim 1, wherein the power unit distributes electric power in the circuit by virtue of electrical pulses, allotting different periods of alternating current per second, depending on power required as set by a user, the priority controller and the electronic processor unit.
 7. The electrode boiler according to claim 1, wherein based on information received from the water sensors located in an input and an output of the plastic core, the electronic processing unit distributes electric power set by a user through the power unit in order to achieve a desired water temperature at the output.
 8. A liquid heating system, comprising: a metal rod; a plastic core surrounding the metal rod; a metal neutral spacer, to maintain the metal rod fixed with respect to the plastic core; curved metal plates screwed with screws to and inside of the plastic core and arranged around the metal rod so as not to touch each other; and electrodes connected -by the screws to the metal plates, the electrodes are arranged to be connected to a power unit to receive electrical power by virtue of electrical pulses, allotting different periods of-alternating current per second, whereby, the heating system is arranged to heat liquid flowing through the plastic core.
 9. A liquid heating system according to claim 8, further comprising area sensors and liquid temperature sensors located at an input and at an output of the plastic core, to measure the area temperature and the liquid temperature of the input liquid and of the output liquid.
 10. A liquid heating system according to claim 9, further comprising an electronic processing unit, to receive the area and liquid sensor measurements and control the power supply to the metal plates to regulate the liquid temperature.
 11. A liquid heating system according to claim 10, further comprising a circulator to circulate the liquid and stream it to radiators via a network of pipes.
 12. A liquid heating system according to claim 11, wherein the circulator is configured to operate when water temperature reaches 15° C. and gradually increases the water circulation speed until water reaches 40° C.
 13. A liquid heating system according to claim 10, further comprising a priority controller, to receive required power loads from the heating unit and from other appliances and regulate the operational power load of the heating unit when the heating unit is used simultaneously with the other appliances.
 14. A liquid heating system according to claim 13, wherein the power unit distributes electric power to the electrodes in response to one or more of user settings, data received from the area and liquid sensors and from the priority controller.
 15. A liquid heating system according to claim 8, wherein the electrodes are connected to a single-phase power supply of the power unit.
 16. A liquid heating system according to claim 8, wherein the electrodes are connected to a three-phase power supply of the power unit, each phase connected to a different curved metal plate.
 17. A liquid heating system according to claim 8, wherein the liquid is water.
 18. An electronic processing unit comprising a processor and a memory, the memory configured to store operation program instructions, the processing unit receiving data from water and area sensors of a heating unit and from a priority controller, and configured to generate control commands in response to the stored instructions and the received data, the control commands to be sent to a power unit to power the heating unit.
 19. The electronic processing unit according to claim 18, further comprising the priority controller, the priority controller configured to be coupled to the heating unit, the power unit and to one or more energy-consuming appliances, the priority controller comprising a microcontroller, the priority controller configured to measure the consumption of power of the one or more appliances and generate information to be used by the power unit to regulate the power provided to the heating unit.
 20. The electronic processing unit according to claim 18, wherein the priority controller generates information so that the power unit reduces the power provided to the heating unit in response to information received from a facility-panel board concerning excessive power consumption of the appliances of the facility. 